Skylight construction

ABSTRACT

The skylight may be of the domed-type or flat-type and of single or double glass (acrylic or other transparent or translucent plastic) construction. The skylight fits within an opening in a roof or the like and has a peripheral curb of an extruded rigid thermoplastic, such as polyvinylchloride (PVC), which is fixed to the roof construction about the opening. The rigid thermoplastic curb has a top co-extruded flexible thermoplastic (such as PVC) gasket integral with the curb and compressible against the edge of the glass or plastic dome or panel. There is also provided a second flexible integral co-extruded thermoplastic gasket adapted to contact a retainer secured to the curb for retaining the dome or panel on the curb. The rigid curb is of a thermoplastic in the shore &#34;D&#34; durometer hardness scale, while the flexible gaskets are of a thermoplastic in the shore &#34;A&#34; durometer hardness scale. A heat platten welding technique, which would most commonly be used in welding the curb frame mitres, would also weld the gaskets simultaneously for a continuous seal. Other less commonly used thermoplastic welding techniques, such as ultrasonic, hot gas, high frequency and friction, could be employed to accomplish the simultaneous bond at the corners.

.Iadd.This application is a continuation, of application Ser. No.879,280, filed June 25, 1986, abandoned. .Iaddend. This application is acontinuation of application Ser. No. 148,974, filed May 12, 1980,.Iadd.abandoned .Iaddend.which in turn is a continuation of Ser. No.923,245 filed July 10, 1978.Iadd., abandoned.Iaddend..

BACKGROUND OF THE INVENTION

The present invention relates in general to an improved skylightconstruction, and is concerned, more particularly, with an improved curbframe construction which provides an improved thermalized skylight whichis preferably for residential use.

The typical prior art skylight curb frame is made of a metal materialsuch as an extruded aluminum. See for example, U.S. Pat. No. 4,073,097.These curb frames certainly provide an adequate support, however, theypermit heat conduction therethrough either from the inside of thebuilding to the outside or vice versa. Furthermore, in cold weatherthere is a tendency for condensation to form on the glass panels oracrylic dome because of an insufficient temperature differential betweenthe inside and outside of the panels or domes.

Accordingly, one object of the present invention is to provide animproved skylight construction having, in particular, an improved curbframe construction.

Another object of the present invention is to provide an improvedthermalized skylight preferably for residential use.

A further object of the present invention is to provide an improvedskylight construction wherein the curb frame may be constructed of arelatively rigid thermoplastic material such as polyvinylchloride.

Still another object of the present invention is to provide an improvedskylight curb frame construction combining a curb of a rigidthermoplastic in combination with a flexible thermoplastic forming oneor more gaskets for sealing the curb frame to at least the dome or panelassociated therewith.

Still another object of the present invention is to provide an improvedmethod of construction of a skylight incorporating composite integralrigid and flexible thermoplastic sections and incorporating a weldingtechnique adapted to weld both the curb and the gasket to provide acontinuous seal.

The forming of a positive seal is important with regard to skylightconstruction. Air exfiltration out of a skylight due to the suctionpressures caused by winds is an important factor in the total energyeffect on a building when a skylight is used. Thus, the use of thisspecial composite PVC is important from the standpoint of energyconservation.

Accordingly, another object of the present invention is to provide askylight construction that is characterized by being energy-saving.

SUMMARY OF THE INVENTION

To accomplish the foregoing and other objects of the invention, there isprovided a skylight construction adapted to be fitted into an opening ina building such as the roof of a residential house. This skylightconstruction comprises a curb frame extending about the opening andhaving means for receiving nails or the like for securing the frame inplace about the opening. In one embodiment, one, two or more transparentor translucent thermoplastic domes cover the opening and extend at theedge to the curb frame. In another embodiment the dome is replaced byone, two or more glass panels. A retainer extends about the periphery ofthe skylight for holding the dome or panel on the curb frame. Inaccordance with the invention the curb frame is constructed of a rigidplastic, preferably polyvinylchloride (PVC). The PVC curb frame is heatwelded at the corners of the frame and has integral therewith at leastone gasket formed of a flexible portion of PVC or the like for sealingbetween the curb frame and the covering means over the opening. The curbframe is constructed preferably of a rigid PVC having a hardness in theshore scale "D", while the gasket is of a flexible PVC having a hardnessin the shore hardness range "A". One important feature of the presentinvention is that a heat platten, high frequency, ultrasonic or otherthermoplastic welding technique may be used to weld the curb, and alsoat the same time weld the gasket for a continuous seal. This provides anextremely tight skylight construction which is an energy-saving featureof the invention. The curb frame preferably also includes a secondgasket that is flexible, integral with the curb frame and contacts theretaining means to form a seal therewith. The curb frame may have ahollow construction, preferably has weep holes holes therein, andincludes means on the inner side thereof defining a condensation gutter.

BRIEF DESCRIPTION OF THE DRAWINGS

Numerous other objects, features and advantages of the invention shouldnow become apparent upon a reading of the following detailed descriptiontaken in conjunction with the accompanying drawings, in which:

FIG. 1 is a cross-sectional view of a domed skylight constructionshowing only a portion of the pair of domes that are used;

FIG. 2 is a somewhat enlarged view of the curb frame constructiondepicted in FIG. 1;

FIG. 3 is a plan view of a fragment of the skylight construction showingthe corner seal;

FIG. 4 is a cross-sectional view similar to the view of FIG. 1 but foran alternate embodiment of a flat skylight construction;

FIG. 5 shows in cross-section, the detail of the curb frame of FIG. 4;

FIG. 6 is a plan view showing a fragment of the skylight construction ofFIG. 4.

DETAILED DESCRIPTION

Referring now to the drawings, FIGS. 1-3 show a first embodiment of theinvention wherein the skylight is in the form of a domed skylight. Thesecond embodiment is shown in FIGS. 4-6 and is a flat skylightconstruction.

In the first embodiment shown in FIGS. 1-3 the domed skylightconstruction spans an opening 10 which may be of square or rectangularshape and defined in part by upright walls 12. A finish material 14 mayalso be provided on the inside of the opening 10.

The skylight construction in the first embodiment includes a pair ofdomes 16 and 18 which are preferably acrylic thermoplastic domes, a curbframe 20 of a thermoplastic which is preferably polyvinylchloride (PVC),and a retainer 22. FIG. 2 is a cross-sectional view showing the curbframe. FIG. 3 shows a corner of the frame of FIG. 2 depicting the cornersealing arrangement.

About the wall 12 there may be provided a flashing or roofing felt strip24 which extends along the outer surface of the wall and about the topthereof as depicted in FIG. 1. The curb frame 20 may be extruded instraight sections and is secured on the top of the wall 12 over theflashing strip 24. The curb frame 20 may be secured to the wall 12 bymeans of a number of nails 26 which extend through the flange 28 of thecurb frame 20. In addition to the downwardly depending flange 28, thecurb frame also includes a base wall 30 and a singular or plurality ofupright walls defining trough 34 and providing support for domes 16 and18. At the upright wall or walls there is the glazing seal gasket 48. Ahorizontal element 36 may also be provided. The bottom wall 30 may havenipples 38 to provide embeddment in mastic and to define the skylightwell opening. As depicted in FIG. 1, a mastic 40 may be laid between theflashing strip 24 and the base wall 30. In the trough 34 there ispreferably disposed a moisture absorbent material 42 which may be acotton or other fibrous batten or the like. The trough 42 with theabsorbent material is for receiving any condensation from the dome 18and collecting this condensation. The curb frame is preferably alsoprovided with openings 44 and 46 spaced therealong which are weep holesfor any excess water permitting the water to be removed from the curbframe.

The extruded curb frame is constructed of a weatherable rigidthermoplastic material, such as a rigid PVC compound of a ASTM-D 1784-69type 1334-C mady by B. F. Goodrich Company of Cleveland, Ohio. Thespecific gravity of this material is 1.46 or on that order. The materialhas a durometer D hardness of 82±3. The tensile strength is 6200 lbs.per sq. inch and the tensile modulus is 355,000 p.s.i. The IZOD impactat 32° F. is 1.781 lbs. per inch. The heat distortion at 264 p.s.i. is163° F.

The curb frame, also includes a top cup-shaped gasket 48 and a side edgegasket 50. Both of these gaksets integrally form with the curb frame butare of a weatherable flexible co-extrusion material such as GEON No.83741 PVC compound. This compound has a specific gravity of 1.36 orthereabouts and has a durometer A hardness of 72±3. The tensile strengthis on the order of 1550 p.s.i. and the tensile modulus is 675 p.s.i. Theultimate elongation is 310 and the brittleness temperature is -35° F.

The curb frame also includes an internally threaded recess 52 whichreceives bolt 54 for securing the retainer 22 to the curb frame 20. Itis noted that the gasket 50 may be slightly deflected and seals againstthe wall 56 of the retainer. The top wall 58 of the retainer pressesagainst the edges 17 and 19 of the respective domes 16 and 18. Acompressible seal 60 is preferably sandwiched between the edges 17 and19 and the edge 19 rests upon the cup-shaped gasket 48 which compressesto seal against the dome. A single dome 16 may be sufficient for certainapplications, and in such case the seal 60 and dome 18 are not required.

FIG. 3 shows a corner of the construction wherein two straight sectionsof extruded curb frame are joined. These sections are joined to form thesquare or rectangular overall configuration of the curb frame. Thejoining is accomplished preferably by a heated platten welding techniquewhich welds the section of curb frame at the same time also welding thegaskets 48 and 50.

FIGS. 4-6 show the second embodiment of the present invention in theform of a flat skylight construction which spans an opening 110 whichmay be of square or rectangular shape and defined in part by uprightwalls 12 and horizontal walls 14.

The skylight construction in the second embodiment includes a pair ofglass plates 116 and 118, a curb frame 120, of a rigid thermoplasticsuch as polyvinylchloride (PVC), and a retainer 122. FIG. 5 is across-sectional view showing the design of the PVC curb frame. FIG. 6shows a corner of the frame of FIG. 5 illustrating the corner sealingarrangement in accordance with the invention.

Roofing felt or other sealing layer 124 extends over the top surface ofroof sheathing 14. The curb frame 120 is preferably extruded in straightsections and is secured on the top of the layer 124. The curb frame 120may be secured to the roof sheathing 14 by means of a number of nails126 which extend through the flange 128 of the curb frame 120. Inaddition to the outwardly extending flange 128, the curb frame alsoincludes a base wall 130 and a singular wall or plurality of uprightwalls which hold the glazing 116 and 118, and threaded recess 152 abovebase wall 130. At the top of the upright wall or walls there is anintegral co-extrusion glazing seal gasket 148. A horizontal element 136may also be provided. The bottom wall 130 may have nipples 138 toprovide embeddment in mastic and to define skylight well opening. Asdepicted in FIG. 4, a mastic 140 may be laid between the layer 124 andbase wall 130. In the trough 134 there is preferably disposed a moistureabsorbent material 142 which may be a cotton or other fibrous batten orthe like. The trough 142 with the absorbent material is for receivingany condensation from the panel 118 in collecting this condensation. Thecurb frame is preferably also provided with openings 144 and 146 spacedtherealong which are weep holes for any excess water permitting thewater to be removed from the curb frame. The extruded curb frame may beconstructed of a rigid thermoplastic material of the same type describedin connection with the first embodiment.

The curb frame also includes a top cup-shaped gasket 148 and a side edgegasket 150. Both of these gaskets are integrally formed with the curbedframe but are of a flexible thermoplastic material which may be of thetype described in connection with the first embodiment of thisinvention.

The curb frame also includes an internally threaded recess 152 whichreceives bolt 154 for securing the retainer 122 to the curb frame 120.The gasket 150 is slightly deflectable and provides a seal against thewall 156 of the retainer. The top wall 158 of the retainer pressesagainst the edge 117 of the panel 116. A seal 160 is preferablysandwiched between the edges 117 and 119 when two glazing panels arerequired. However, in certain instances seal 160 and bottom glazing 119can be eliminated. The edge 119 rests upon the cup-shaped gasket 148which compresses to seal against the panel.

FIG. 6 shows a corner of the construction wherein two straight sectionsof extruded curb frame are joined. These sections are joined to form thesquare or rectangular overall configuration of the curb frame. Thejoining is accomplished preferably by a heat platten welding techniquewhich welds the section of curb frame at the same time also welding thegaskets 148 and 150.

One of the important features of the present invention is the specialconstruction of the curb frame of this invention which is preferably ofa thermoplastic material such as polyvinylchloride. The construction ofthe curb frame may also be of any other type of thermoplastic material.The majority of the curb frame is constructed of a plastic that issubstantially rigid to provide the basic support. On the other hand, thegaskets, such as gaskets 48 and 50 are of a quite flexible material. Forexample, FIGS. 1 and 2 show the different positions of the gasket 48both in its normal position in FIG. 2 and in its compressed position inFIG. 1.

The domed glazing described in conjunction with thermoplastic frame 28may also be used on frame 120, and the flat glazing described inconjunction with thermoplastic frame 120 may also be used on frame 28.

What is claimed is:
 1. A skylight construction of an opening in abuilding comprising;a curb frame extending about the opening and havingmeans for receiving a means for securing the frame in place about theopening, translucent or transparent means covering the opening andextending at its edges to the curb frame, means for retaining thecovering means on the curb frame, said curb frame being constructed of arigid thermoplastic material having co-extruded and integral therewithat least one gasket of flexible thermoplastic material for providing aleak-proof seal between the curb frame and covering means, said rigidthermoplastic material forming the curb frame and said co-extrudedflexible thermoplastic material being commonly heat welded to join thecurb frame mitres and also simultaneously weld the gaskets at the curbframe mitres to provide a continuous seal about the entire curb frame.2. A skylight construction as set forth in claim 1 wherein said rigidthermoplastic is a rigid PVC and said flexible thermoplastic is aflexible PVC.
 3. A skylight construction as set forth in claim 2 whereinthe rigid PVC has a hardness which is within the shore "D" hardnessscale and the flexible PVC has a hardness which is within the shore "A"hardness scale.
 4. A skylight construction as set forth in claim 1wherein said covering means includes at least one plate means.
 5. Askylight construction as set forth in claim 1 wherein said coveringmeans includes at least one acrylic dome.
 6. A skylight construction asset forth in claim 1 wherein both said curb frame and gasket are heatsealed at the corners of the construction.
 7. A skylight construction asset forth in claim 1 wherein said gasket is cup-shaped.
 8. A skylightconstruction as set forth in claim 1 wherein said curb frame has meanson the inner side thereof defining a condensation gutter.
 9. A skylightconstruction as set forth in claim 1 including a second gasket that isflexible, integral and co-extruded with the curb frame and contactingthe retaining means to form a seal therewith.
 10. A skylightconstruction as set forth in claim 1 wherein said retaining meansincludes a retainer having one side contacting the edge of the coveringmeans and another side extending over the curb frame.
 11. A skylightconstruction as set forth in claim 10 including securing means forsecuring the retainer to the curb frame sandwiching the edge of thecovering means between the curb frame and the one side of the retainer.12. A skylight construction for an opening in a building comprising;acurb frame extending about the opening and having means for receiving ameans for securing the frame in place about the opening, translucent ortransparent means covering the opening and extending at its edges to thecurb frame, means for retaining the covering means on the curb frame,said curb frame being constructed predominantly of a rigid thermoplasticmaterial having linearly extending sides defining a substantially flattop wall having a gasket co-extruded and integral therewith constructedalso a thermoplastic material but one that is flexible, said gaskethaving a non-compressed position wherein the gasket extends its maximumdistance from the top wall, and a compressed position, being compressedin a direction normal to the top wall by the engagement with thecovering means, wherein the gasket is compressed to seal between thecurb frame and covering means, said curb frame having inner and outersides and defined at least in part by a plurality of walls includingsaid top wall which together define a hollow duct substantially closedexcept for weep holes permitting communication between the inner andouter sides of the curb frame, said hollow duct overlying a support wallfor the curb frame and underlying said gasket and covering means.
 13. Askylight construction as set forth in claim 12 wherein said curb framehas means in its top wall defining a recess for receiving a securingmeans forming a part of the retaining means for the covering means. 14.A skylight construction as set forth in claim 13 wherein the securingmeans include a securing bolty passing through the retainer and into therecess which is threaded to receive the bolt.
 15. A skylightconstruction as set forth in claim 14 including parallel inner and outerside walls of the frame side each having at least one weep hole therein.16. A skylight construction as set forth in claim 12 wherein said gaskethas substantially one connection point to the frame and is cup-shapedhaving at least a partially annular edge contacting the covering means.17. A skylight construction as set forth in claim 12 wherein said gaskethas an area of connection to the frame that is smaller than the sealingarea of the gasket to the covering means.
 18. A skylight construction asset foth in claim 12 wherein said plurality of walls includes inner andouter vertical walls with the weep holes in these respective inner andouter vertical walls.
 19. A skylight construction for an opening in abuilding comprising;a curb frame extending about the opening and havingmeans for receiving a means for securing the frame in place about theopening, translucent or transparent means covering the opening andextending at its edges to the curb frame, means for retaining thecovering means on the curb frame, thermoplastic material having linearlyextending sides defining a substantially flat wall having a gasketco-extruded and integral therewith constructed also a thermoplasticmaterial but one that is flexible, said gasket having a non-compressedposition wherein the gasket extends its maximum distance from the topwall, and a compressed position, being compressed in a direction normalto the top wall wherein the gasket is compressed to seal between thecurb frame and covering means, said gasket having a fixed connectionbase for connection to the curb frame with the flexible portion of thegasket extending from the base and flexible and compressible in saidnormal direction, said rigid thermoplastic material forming the curbframe and said co-extruded flexible thermoplastic material beingcommonly heat welded to join the curb frame mitres and alsosimultaneously weld the gaskets at the curb frame mitres to provide acontinuous seal about the entire curb frame.
 20. A skylight constructionas set forth in claim 19 wherein said gasket is elongated to extendalong each side of the curb frame being secured along a single base edgewherein the gasket is held fixedly.
 21. A skylight construction as setforth in claim 20 wherein the gasket is cup-shaped in cross-sectionhaving opposite extending linear edges that flex to seal.
 22. A skylightconstruction as set forth in claim 20 wherein said gasket has an area ofconnection to the frame that is smaller than the sealing area of thegasket to the covering means.
 23. A skylight construction as set forthin claim 19 wherein the gasket extends around all sides of the curbframe.
 24. A skylight construction as set forth in claim 19 wherein saidtop wall is disposed substantially horizontally and the flexible portionof the gasket overlies the top wall and is compressed by the weight ofthe overlying covering means toward the top wall.
 25. A skylightconstruction as set forth in claim 24 wherein said gasket is cupped withopposite extending linear flexible edges that overlie said top wall andthat are compressed theretowards.
 26. A skylight construction for anopening in a building comprising;a curb frame extending about theopening and having a means for receiving a means for securing the framein place about the opening, translucent or transparent means coveringthe opening and extending at its edges to the curb frame, means forretaining the covering means on the curb frame, said curb frame beingconstructed predominantly of a rigid thermoplastic material havinglinearly extending sides defining a substantially flat top wall having agasket co-extruded and integral therewith constructed also athermoplastic material but one that is flexible; said gasket having anon-compressed position wherein the gasket extends its maximum distancefrom the top wall, and a compressed position, being compressed in adirection normal to the top wall by the engagement with the coveringmeans, wherein the gasket is compressed to seal between the curb frameand covering means, said curb frame having inner and outer sides anddefined at least in part by a plurality of walls including said top wallwhich together define a hollow duct substantially closed, said hollowduct overlying a support wall for the curb frame and underlying saidgasket and covering means, said hollow duct providing a dead air spaceto provide increased resistance to thermal conductivity. .Iadd.
 27. Askylight construction as set forth in claim 26 wherein said gasket hassubstantially one connection point to the curb frame and is cup-shapedhaving an edge contacting the covering means. .Iaddend..Iadd.28. Askylight construction as set forth in claim 26 wherein said rigidthermoplastic material forming the curb frame and said co-extrudedflexible thermoplastic material being commonly sealed to join the curbframe mitres and also simultaneously secure the gaskets at the curbframe mitres to provide a continuous seal about the entire curb frame..Iaddend. .Iadd.29. A skylight construction as set forth in claim 26wherein said curb frame has means on the inner side thereof defining acondensation gutter. .Iaddend. .Iadd.30. A skylight construction as setforth in claim 29 wherein said condensation gutter is formed in part bya wall forming said hollow duct. .Iaddend. .Iadd.31. A skylightconstruction as set forth in claim 26 wherein said rigid thermoplasticis a rigid PVC and said flexible thermoplastic is a flexible PVC..Iaddend. .Iadd.32. A skylight construction of an opening in a buildingcomprising;a curb frame extending about the opening and having means forreceiving a means for securing the frame in place about the opening,translucent or transparent means covering the opening and extending atits edges to the curb frame, means for retaining the covering means onthe curb frame, said curb frame being constructed of a rigidthermoplastic material having co-extruded and integral therewith a leastone gasket of flexible thermoplastic material disposed between the curbframe and covering means, said rigid thermoplastic material forming thecurb frame and said co-extruded flexible thermoplastic material beingcommonly sealed to join the curb frame mitres and also simultaneouslysecure the gasket at the curb frame mitres to provide a continuous sealabout the entire curb frame. .Iaddend. .Iadd.33. A skylight constructionas set forth in claim 32 wherein said curb frame has a plurality ofwalls including a top wall for supporting said gasket. .Iaddend..Iadd.34. A skylight construction as set forth in claim 33 wherein saidplurality of walls define a hollow duct that is substantially closed..Iaddend. .Iadd.35. A skylight construction as set forth in claim 34wherein said hollow duct overlies a support wall for the curb frame andunderlies said gasket and covering means. .Iaddend. .Iadd.36. A skylightconstruction as set forth in claim 32 wherein said rigid thermoplasticis a rigid PVC and said flexible thermoplastic is a flexible PVC..Iaddend. .Iadd.37. A skylight construction as set forth in claim 32wherein both said curb frame and gasket are heat sealed at the mitres..Iaddend.